Method of producing sheet metal shells for automobile radiators



G. E. IRELAND Jufly F17, 1934.

METHOD OF PRODUCING SHEET METAL SHELLS FOR AUTOMOBILE RADIATORS 4 Sheet-Sheet 1 Filed April 4, 1952 W 4 ML 5 UR 5 Q R m a G. E. IRELAND 1,966,723

METHOD OF PRODUCING SHEET METAL SHELLS FOR AUTOMOBILE RADIATORS Filed April 4, 1932 4 SheetsSheet 2 i 11. 5/ all F Firv 75.

I 650/7655. //?EL,4NZ7

y 7, 1934. G. E. IRELAND 7 1,966,723

METHOD OF PRODUCING SHEET METAL SHELLS FOR AUTOMOBILE RADIATORS Filed April 4, 1932 4 Sheets-Sheet 3 July 17, 1934. G. E. IRELAND 1,966,723

METHOD OF PRODUCING SHEET METAL SHELLS FOR AUTOMOBILE RADIATORS Filed April 4, 1932 4 Sheets-Sheet 4 Fl 7- J M Patented July 17, 1934 METHOD OF PRODUCING SHEET SHELLS FOR AUTOlVIOBILE RADIATORS George E. Ireland, Toledo, Ohio; Edith May Ireland and Dwight B. Ireland, executors of said George E. Ireland, deceased Application April 4,1932, Serial-No, 602,884

10 Claims.

This invention relates to a method of producing sheet metal shells for automobile radiators and other structures requiring an open framelike shell. In the production of radiator shells it is customary to provide a preliminary partially formed shell or blank which is then subjected to the action of forming devices to impart thereto the final shape of the shell and the present method relates primarily to the production of this preliminary partially formed shell.

One method commonly employed in the production of such preliminary shells consists in drawing a large flat sheet of metal into a pan-like form, removing the major portion of the bottom of the pan to provide an-open shell and forming the shell in the desired preliminary shape. This method is not only wasteful of metal, because of the large part of the sheet which must be cut away, but the drawing operation requires the use of inner-and outer dies and the exterior surface of the shell is usually marred by die marks and wrinkles which makes it difficult, if not impossible, to impart thereto a fine finish.

Another method of producing radiator shells is shown in Patent'No. 1,808,731, granted to me June 2, 1931. According to this method a series of substantially U-shaped strips are cut from a large flat sheet of metal, bent to-the desired form and the ends of the strip connected by a separately formed bar which is welded thereto and bent to the desired shape, thus producing a preliminary partially formed shell which is then given its final form by suitable dies. While this method efiects a substantial saving of metal over the first mentioned method there is still considerable waste and the production of the preliminary shell requires a considerable time and labor. Both methods require the use of large wide sheets of metal. The surface characteristics of metal which is rolled in large sheets differs materially from the surface characteristics of metal which is rolled in relatively narrow strips and the surface of the narrow strip will take a much higher finish than will the surface of the large sheet.

One object of the present invention is to provide a method whereby radiator shells and the like may be produced quickly and without waste of metal, thereby enabling them to be produced at low cost.

A further object of the invention is to provide a method whereby radiator shells and the like may be produced without marring the exterior surface thereof -A further object of the invention is to provide a method whereby radiator shells and the like may be produced from relatively narrow strips of metal.

single preliminary shell.

Other objects of the invention will appear as the method is described in detail.

In the accompanying drawingsv Fig. l illus trates the initial blank from which the shell is formed; Fig.- 2 shows the blank bent to its initial form prior. to the forming operation; Fig. 3 shows the blank or endlessstructure-of Fig. 2 shaped to provide two partially formed shells; Fig. 4 shows the shaped blank of Fig. 3 divided to separate thetwo partially formed shells; Fig. 5 is a planview of a forming device suitable for the preliminary forming operation; Fig. 6 is a sectiontaken on the line 6-6-of Fig. 5, showing the expanding device in position prior to the first Fforming operation; Fig. 7 is a similar sectionshowing the positions ofthe parts at the end of the first forming operation; Fig. 8 is a similar section showing the positions of the parts at the end of the second forming operation; Fig. 9 .is a section taken on the line 9--9 of Fig. 5 with the parts in the positions shown in Fig. '7; and Figs. 10, '11 and 12 are sectional detail views of the ,final forming dies showing the successive steps in the final forming' operation. 7

connected one to the other.

The two shells are then separated by a circumferential cut and are acted upon separately by another forming device to impart the final shape thereto. While the method is designed primarily for the production of radiator shells it will be obvious that it maybe used forproducingopen framelike shells er various kinds and .that th8 "d8t&il$ thereof may be varied as circumstances demand.

I prefer to produce two preliminarymartial'ly formed shells simultaneously. For this purpose I employ a relatively narrow strip of sheet metal, as shown in Fig. x1,5612...sfi'fiicier'it width to enable two preliminary-shells to be formed thereof, side by side. This stripof-metal-is bent and its ends united, prferablybybuttwelding, to provide an endless structure :orband 15 of a shape corresponding approximately to the outline of the partially formed prel'rminaryshell. any suitable apparatus may be employed for imparting the desired shape to this endless band but that Therein illustrated iis welladapted for that purpose. It consists of internahrliemembers only the outer: surfacezof the en'dless bandv being unsupported throughout the forming :operation. Preferablyit. consistsiof az pluratlityfof relatively movable die members having an-exterior contour adapted toiex-pand or. stretch the band to the desired shape when ztheidie members are moved :outwardly. Each'Idie memberwisseparately supported fora-movement with "relation to the other die' members and expanding "devices or plungers care arranged to cooperate with the die members to impart-operative movement thereto. in .thegpresent apparatus the forming device comprises side .or lateral .die members to engage the :longitudinal walls of the endless .band and, for 'arreason which will hereafter appear, it is ipreferable 'that these side: die :membersshouldconsist of itwo parts, as shown at 16 and lGaaand-l'l :aridl'la. vAt the ends of the:- side 'die 'membersware' end'die members 18and l9=and-overlapping the respective side and 'end 'die :memberszare corner die members 20,-21,'22,'and=23. The-die members 16, 17,'18,-20:and 21, at one :end ofrtherapparatus, are slidably mounted uponaibase 24sand, in the present instanca each'die member has secured thereto aslide bar orgib 25' which isrslidably mounted in a groove 26-in the base 524, the slide bars being of suflicient 'length to hold the respective die members against all .turning movement.

The die'members lfiaw-arid 17a, 19,"-22= and 23, at the other end of the-"apparatus, arescarried by a, plate '27 which is slidably 'mounted upon the base 24::and' isrheldrnormallyiin its-I innermost positionvby springsi 2B "which, 'in thepresent instancegare :mounted in channels in the--base 24. The several .die members rarefslidably connected with the slidet'plate 27 .by means :of slide ban-s29 and-grooves 30isimilarto the'slide bars i :andzzgrooves 25 :and :26, with the fexception that the grooves are formedvin the slide plate .27. insteadofxin the basepan'd' each groove 1 30"has-an end" wall or abutment" 31 whicluforms astop to limitthe outward movementof thedie member for that group. "outwardz'or operative movement is imparted: to Z: the 'die LmembersJby means of. an. expanding .device. which carried by a mainram 32 and, in the present-instance, consists of two parts 33 and34, the:part-'33 beingrigidly secured to the ram and the part- 34 being carried by a plate i35-i'whichvis slidably mountedi on the ram? for movement in aldirection away fromithel p'art 33. plate 35 is=acted inclined surfaces 40 in the side die members 16, 16a and l? and 17a. faces are so arranged that upon the downward The several inclined surmovement of the rain-the side and end die members will be -move'd outwardly simultaneously. The corner die members have no direct contact with the expanding device but each of these corner die membershas a surface overlapping an inclined surface 41 on the adjacent end die 'memberand an inclined surface 42 on the adjacent side die member the arrangement being such that the outward movement of the end and side idiemembers willimpart outward movement 'I-tO -IEIIG corner .die c'members along .lines :diagonal tothe-rlines .ofrxmovement to the end 'an'ds'side members, thus causing the members to press-toutiand form. the. corner portions of the :band. I I Thezseveral .die. members-are; retained norimallyzin: theirilnn'ermost; or retracted positions, this being preferably accomplished by springs, mot'ihere'shown. When the dieunembers are in their retracted positions and the ram, has beenelevatedthe endlessstructure or band 15 is placed-about the die members with its lower edge resting upon the base 24 and plate-27, as shown inJFig. .6. the inclinedsurfaces of the expanding device tozengage. the inclined surfaces on the respective idieimembers'and thus force the same outwardly to .the :positionsshown in Fig. 7, thereby expandingror: stretching the. metal of the band to causethe same itoconform to .the contour of thenexteriorsurfaces. of the die members. .In the-formation:ofna-shell of the type here -illus- .trated thevintermediate: circumferential portion of the band 15 is drawn outwardlywa'considerable distance beyond theupperand lower edges of-the bandso that the zupper'and-lower. portions of the band sloperfrom.thecentral circumferential --line inwardly toward theedges thereof.

Q-InLa :mdiato i shell of the; type here illustrated that end of the shell whichis at the top ofithe radiator .is..deeper than-the other portions v:of thev shelLand, for the purposeof im parting this deeper. and difierentish'ape 'to the oneen dlp ortion of the band l5 with out' removing .'.the band from the'fform'ing ,device which hasimpar'ted'th'e initialfdrmth'ereto, I cause the die members which arec'arii'ed by the plate 27 to move iengtn ise o'f'the apparatus toward that end of thelban'd which 'is to be further expanded. This is"accomplishe'd by means of a"secondary expanding .devi'ce 43"carrie'd by supplemental OIil1'l'i6l"'1'all'i "44 which is oper ate'd "independently of "the mainram. This 's'econdary'expanding device ha's'at its "lower "end an inclined"surface 45 to" engage-amoflesponding inclined-surface 46'-o-nthe part" 34 or" the main expanding device, whereby downward movement of 'the secondary expanding device will -rnove'-'-the part "34 of the "main expanding device away-from the -part"33'*thereof. That side 'of the secondary expandingdevice opposite the inclined surface 45 is flat and engages" the flat surface of' the part 33 of the main expanding device *so that the last mentioned 'part of The ra rnuis then lowered to cause the expanding device and the die members controlled thereby are positively held against movement. The downward movement of the main expanding device has carried the inclined surface 37 thereof beyond the inclined surface 38 .of the end expanding member lQ-and the flat tion to the plate and the plate itself is caused to move, thus carrying all the die membersin a straight line toward that endof the band or structure 15 which is to be further expanded and thereby drawing the intermediate portion of this end of the band. a further distance beyond the edges thereof and causing that end .of the band to assume the shapeshown at the lefthand end of Fig. 8. This completesthe formation of the band. and the rams are elevated, the movable member 34 of the main expanding device and the plate 27 .are restored to their initial positions and the several, die members are retracted, thereby releasing the formed band and permitting the same to be removed. The band is now in the form shown in Fig. 3 and it comprises two partially formed shells which, in the present instance, are identical in construction but are arranged in reverse positions. This formed band is then severed along a central circumferential line,-as shown in Fig. 4, to separate the two partially formed shells one from the other. This may be accomplished by any suitable cutting device, such as a rotary cutting tool.

The movement of the plate 27 and the die members carried thereby will, of course, move the side die members 16a and 17a, respectively, from the side die members 16 and 17 and in order to prevent any deformation of the side walls of the shell I have provided the adjacent ends of the die members of each pair of side die members with interleaved fingers or tenons or" such length that they will remain in overlapping relation when the die members are separated.

The two preliminary partially formed shells are then individually subjected to the action of the final forming device. This forming device may be of any suitable character but in Figs. 10, 11 and 12 I have shown a portion of a forming device similar to the final forming device shown in the above mentioned patent. This forming device comprises two fixed die members 47 and 48 so arranged that when the endless partially formed shell is placed thereon it will be supported by its marginal portions on the two die members, it being understood that these die members are continuous and similar j in shape to the outline of the shell, so that the shell will seat therein and will be retained in proper position thereon, as shown in Fig. 10. Movable die members 49 and 50, carried by a ram 51, are moved downwardly into engagement with the marginal portions of the partially formed shell, which is shown at 52, and serve to shape these marginal portions and to firmly clamp the shell in position, as shown in Fig. 11. A secondary forming member or die 53, carried by a supplemental ram 54, is then moved downwardly into engagement with the intermediate portion of theshell, which intermediate portion is unsupported on its lower side. This secondary die will stretch or expand the metal and draw the same to the shapeshown in Fig. 12,

one-modifications may be necessary or desirable in applying the method to the production of shells having different characteristics.

' Having now fully described my invention what I claim as new and desire to secure by Letters Patent, is:

' 1. The method of forming open shells of sheet metal, comprising bending a flat blank and uniting the ends thereof to form an endless structure, subjecting said structure to the action of a forming device to impart thereto a cross sectional. shape equivalent to two partially formed shells, dividing said structure along a circumferential line to separate said partially. formed shells and then subjecting each partially formed shell to the action of a forming device to'impart a final shape thereto.

2. The method of forming open shells of sheet metal comprising bending a fiat blank and uniting the ends thereof to form an endless structure, expanding said structure by the application of pressure to the innersurface thereof while the outer surface is unsupported to impart to ,each lateral edge portion thereof the shape of a partially formed shell, separating said portions one from the other along an intermediate circumferential line and then separately shaping said partially formed shells to their final form. 1

3. The method of forming open shells of sheet metal comprisingbending a fiat blank and uniting the ends thereof to form an endless structure, subjecting said structure to the action of a forming device to draw an intermediate circumferential portion of said structure outwardly beyond the edges thereof so that the edge portions of said structure will slope inwardly toward the respective edges, severing said structure along an intermediate circumferential line into two parts and forming each part into a finished shell.

4. The method of producing open shells of sheet metal comprising bending a fiat blank and uniting the ends thereof to form an endless structure, subjecting said structure to the action of a forming device to draw an intermediate circumferential portion of said structure outwardly a substantially uniform distance beyond the edges thereof so that the lateral portions of said structure will slope inwardly toward the edges thereof and to then draw said intermediate portion a further distance outwardly beyond said edges at one end only of said structure, severing said structure along an intermediate circumferential line into two parts and forming each part separately into final shape.

5. The method of forming open shells of sheet metal comprising bending a flat blank and uniting the ends thereof to form an endless structure, placing said structure about an expansible forming device having an outwardly extending circumferential portion intermediate the edges of said structure, actuating said forming device to first expand said structure uniformly in all directions and to then further expand one end portion only of said structure, severing said structure along an intermediate circumferential line into two. parts and forming each partsseparately into final shape.

v6. The method ofjproducing'apartially formed blank for an open shell of sheetumeta1 comprising bending a strip of :sheet. metal-andnniting the ends thereof to form :an endless :band, placing said band about a formingidevice' comprising internal die members onlyand then actuatingsaid 'die members to stretch saidtbandto a shape iconforming to the shape of "said die members andithen actuating .a part only of said diemembers, while -said band remains in engagement with .said-Idie member, to further stretch one portion only of said. band.

S7. The .zmethod of :iproducing :radiator ishells comprising the bending'ofa: strip of metal into oblongform andum'ting (the ends thereof .to provide .an 'IEIldlBSS qband, placing. said band about a. forming device comprisinginternal die .membersLin. different directions :only, actuating said die members'to, impart to'said band a substantially uniform cross sectional shape different from the initial-cross sectional shape "thereof,

holding :a ripart .of said .'die :members against movement, actuating another spart :of. said :die members to impart a di'fierent shape to'a portion only of said band, retracting'all of said die members, removing-said band and subjecting said band to the action of otherdle members to complete the formationthereof.

- '8.-The method: of producing radiator shells shapes: toithe upper and; lower .sportionsr'of said band, -removingr-said iband'from :saidxforn'n'ng :device, severing. said band along an .intermediate circumferential line to separate saidupper and lower portionsxand ;then subjecting .said ;portions..separately to :the .action: of a V. forming :device to impart final shape thereto.

:f9.'.fl3he method of :producingradiator ishells comprising bending .a strip of 'sheeti metal of 3." Width-1 sufficient .toiorm two shells and unit- ;ing ithe :ends :of said :strip .to .form' an endless :-band,: placing said band about a forming device comprising-internal:.'die members only, actuatingzsaid die members to sexpandithe: intermediate:cireumferentialzportion :of said :zband outjwardlyabeyond theredges thereof and: touimpart like shapes to the .upper and lower portions of said band;thenlactuatingxazpart only of said idieamembersito'further expandi'one portion of said band; removing said band: fromi said forming device,zsevering said'bandralongan .intermediate circumferential line to separate said .npper anddower portions and then subjecting .said'porlionsseparately to the action of a formmg devicezto: impartiifinalr shape thereto.

:lOjThe method of simultaneously producing two: shells of predetermined "configurationirom .sheet'metal comprising'bending .a' strip -of:;meta1 and uniting the :ends'thereof to form. an endless structure, zexpanding said structure "to .impart 105 theretoza cross sectionalshape 'difierent'from the 'crosssectional shape of the initial endless structure and corresponding'to Jtwo shells connected at itheir adjacent edges, and dividing the "expanded structurerzalong an intermediate 110 circumferential line to separate :said .shells :one from'the other.

GEORGE E. IRELAND. 

